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From Molecules to Materials: Engineering New Ionic Liquid Crystals Through Halogen Bonding

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Published on: March 24, 2018

Dissimilar Materials Bonding Using Epoxy Monolith.

Yuka Sugimoto¹, Yukihiro Nishimura¹, Fai Uehara¹

¹Department of Applied Chemistry, Graduate School of Engineering, Osaka Prefecture University, 1-1 Gakuen-cho, Naka-ku, Sakai, Osaka 599-8531, Japan.

|August 29, 2019

Summary

A novel epoxy monolith enhances polymer-metal bonding. This porous material improves thermal welding strength for thermoplastics bonded to metal plates, demonstrating a versatile dissimilar material joining technique.

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Area of Science:

Materials Science
Polymer Chemistry
Surface Engineering

Background:

Developing robust methods for dissimilar material bonding is crucial for advanced manufacturing.
Traditional bonding techniques often face limitations with polymers and metals due to differing surface properties.
Epoxy-based materials offer tunable properties for surface modification.

Purpose of the Study:

To develop and evaluate a novel epoxy monolith coating for enhancing dissimilar material bonding.
To investigate the bonding performance of various thermoplastics to metal substrates using the epoxy monolith.
To characterize the microstructure and bonding mechanism of the modified interfaces.

Main Methods:

Fabrication of a highly porous epoxy monolith via polymerization-induced phase separation using specific epoxy resins and poly(ethylene glycol) as a porogen.
Characterization of epoxy monolith microstructure (pore size, density) using scanning electron microscopy (SEM).
Application of the epoxy monolith to metal plates and subsequent thermal welding with various thermoplastics.
Evaluation of bond strength using single lap-shear tensile tests and fractographic analysis via SEM.

Main Results:

Epoxy monoliths with tunable pore sizes (1.1-114 μm) and densities were successfully fabricated.
Significantly improved bond strengths (1.2-7.5 MPa) were achieved for thermoplastics bonded to stainless steel and copper plates compared to unmodified systems.
SEM analysis revealed an 'anchor effect' due to polymer chains elongating into the monolith pores, confirming the bonding mechanism.

Conclusions:

The developed epoxy monolith coating is an effective method for enhancing dissimilar material bonding between polymers and metals.
The observed anchor effect, facilitated by the porous structure, is key to the improved bond strength.
Bond strength is influenced by the intrinsic properties of the bonded thermoplastics, with potential for bonding harder plastics using additional aids.